Apparatus for casting



Nov. 2, 1943. c. WESSEL 2,333,286

APPARATUS FOR CASTING Filed May 14, 1941 4 Sheets-Sheet 1 frodezoioz? @fl Z/e sSeZ Nov. 2, 1943. c. WESSEL APPARATUS FOR CASTING Filed May 14, 1941 4 Sheets-Sheet 2 91 mu we m"- Nov. 2, 1943. c. WESSEL APPARATUS FOR CASTING Filed May 14, 1941 4 Sheets-Sheet 5 Nov. 2, 1943. c. WESSEL 2,333,286

APPARATUS FOR CASTING Filed May 14, 1941 4 Sheets-Sheet 4 Patented Nov. 2, 1943 APPARATUS FOR CASTING Carl Wessel, Chicago, 111., assignor to Carl Weasel and Lew W. trustees Cleminson,

Chicago, 111., as

Application May 14, 1941, Serial No. 393,314

16 Claims.

The present invention relates to an improved apparatus for making thin metal sheets or thin plates or metal stock of uniform cross section, and is particularly concerned with the provision of apparatus by means of which such metal sheets or plates may be formed of homogeneous largegrained structure without segregated impurities and with a minimum amount of impurities of any kind.

The present application is a continuation-inpart of my prior applications, Serial No. 251,092, filed January 16, 1939, for Metal castings, methods and machines for-casting the same, now Patent No. 2,287,848, dated June 30, 1942, and Serial No. 370,344, filed December 16, 1940, for Method and apparatus for making drawn metal tubes and metal castings, now Patent No. 2,309,608, dated January 26, 1943;

One of the objects of the invention is the provision of an improved apparatus for casting and .treating metals such as clean scrap or any other metal in ingot form by means of which plates or sheets of metal may be made which have a homogeneous large-grained structure and which are substantially free from segregations of impurities.

Another object of the invention is the provision of an improved apparatus of the class described by means of which cast metal plates or rolled sheets may be made which have a substantial increase of tensile, compression and shearing strength and which have the characteristic of a better degree of.-wrkabi1ity than the metals made according to the methods of the prior art.

Another object of the invention is the provision of an improved casting machine by means of which the defects of the prior art devices, such as blow-holes, inclusions, segregations, faults, cracks, and other defects, are practically eliminated.

Another object of the invention is the provision able to use in small or large plants and which is adapted to produce metallic members having the characteristics of high degree of uniformity of crystalline structure and a uniform smooth outer surface adapted to be polished without necessity for smoothing the surface after casting and before the polishing.

Another object of the invention is the provi- -sion of an improved casting machine by means of which tubular structures may be made having a high degree of uniformity of crystalline structure and by means of which they may be constructed at a minimum cost.

, of an improved casting apparatus which is adapt- Another object of the invention is the provision of an improved apparatus for producing a superior cast metal product or a sheet metal product which is simple and which involves a minimum number of operations so that a minimum amount of capital and labor is required in the production of the articles made by the ap- I and the accompanying drawings, lnwhich similar characters of reference indicate similar parts throughout the several views.

The drawings Referring to the four sheets of drawings:

Figure 1 is a fragmentary, front elevational view of a casting apparatus embodyingthe invention;

Figure 2 ,is a similar side elevational view of the casting apparatus;

Figure 3 is a,vertical sectional view taken on the plane of the line 3-3 of Figure 1 looking in the direction of the arrows, showing the details of structure and interior shape of the mold and ladle;

Figure 4 is a horizontal sectional view taken on the plane of the line 4-4 of Figure 3 looking in the direction of the arrows;

Figure 5 is a view similar to Figure 3 with the parts of the apparatus in the position which they assume during the casting of a thin metal plate;

Figured is a fragmentary top plan view of the ladle and its cover, with the mold removed; and

Figure '7 is a diagrammatic sectional view taken on the plane of'the line |--1, looking in the direction of the arrows, of Figure 6, with the mold shown in dotted lines, showing its position relative to the ladle.

Referring to Figures 1 and 2, the casting apparatus which has been selected to illustrate the invention, preferably includes a movably supported 'ladle indicated in its entirety by the numeral [0, and a mold H directly connected to the ladle l0 and adapted to be moved with it. The ladle i0 is preferably movably mounted on a pair of bearing frame members l2, l3 and is preferably so balanced with respect tothe assembly of the mold H and ladle III, that it will be normally held in upright position as shown in Figures 1 and 2, even when the supply of molten metal in the ladle has been exhausted.

The bearing brackets l2 and I3 may be identical in shape and constructionand therefore only one of them need be described in detail. These brackets are preferably of sufilcient length to permit a maximum degree of pivotal movement of the ladle and mold and may, in some embodiments of the invention, permit full rotation of the mold and ladle throughout 360'. This may be accomplished by providing a pit in the floor l4 between the frame members i2 and I3 and extending forwardly and rearwardly of them, or the frame members 12 and I 3 may be supported in elevated position upon blocks II as shown in Fi8 e 5.

Each frame member preferably has a pair of upwardly extending columns l3, l1, integrally supported by a bottom frame member 13 which has a pair of attaching flanges i3, 23, provided with apertures for receiving the bolts or lag screws 2|. The frame members l3-l3 may be substantially T-shaped in cross-section and at the upper end of the bearing brackets 12 and I3 they are formed with the rectangular opening 22 defined by the frameportions 23-23.

The frame portions 23-23 are preferably provided with threaded apertures for receiving the screw bolts 21-32. Each screw bolt 21 has its inner end engaged in a socket 33 in one of the bearing blocks 34,33, and the screws are held in fixed position by lock nuts 33.

\ The bearing blocks 34, 33 comprise a pair of metal members, which, when assembled as shown in Figure 2, have plane rectangular sides and are formed with a bearing aperture 31. Since the bearing blocks 34, 33 are adiustably supported by ,the screw bolts 21-32, they may be brought into aiinement even after the frame members l2 and I 3 have been secured in place, provided the frame members are also substantially in alinement.

fThe ladle l3 may comprise a substantially cylindrical metal shell, such as the shell 33, having the cylindrical side walls 33 and fiat bottom 43. This metal shell may be linedlwith a layer of suitable insulating material, such as asbestos 4i, covering the inner surface of its side walls 33 and its bottom 43. The asbestos lining 4| supports a second rigid lining 4,2 of a refractory material, such as a ceramic product adapted to withstand the melting temperatures to which the metal is to be sub- Jected. This ceramic lining 42 is provided with an inner chamber 43 which may be substantially cylindrical in shape except that the lower corners are rounded at 44, 45, and the left-hand wall 43 (Figure 3) may be tapered or may be made substantially frusto-conical at its lower portion leading to a substantially frusto-conical cover opening 41 at the top.

The opening 41 'for the cover plug 43 diverges from the cylindrical shape at the left-side where it may be provided with a fiat wall surface at 43 for cooperating with the cover plug 43 to form the walls of a rectangular aperture 33 in the top of the ladle l3.

The cover plug 43 may comprise a frusto-conlcal member of refractory material, such as the same ceramic 42 which is formed to. fit in the frusto-conical opening 41 over the major portion of its outer frusto-conical surface 31. At the right-hand side, the cover plug 43 is formed with a groove 52 which is half-circular at the upper end and which increases in size frusto-conically toward the bottom of the plug. When the plug 43 is assembled with the ladle 13, the aperture 32 at the right-hand side is adapted to provide an upwardly tapered conduit for receiving the burner flame 33 which may be directed downwardly into the ladle from the gas burner 34 to apply heat to the surface of the metal and to reflected upwardly into the mold ii.

At its left side (Figure 4) the cover plug 43 is formed with a groove 33 which is rectangular in cross-section and which at its upper end forms a discharge opening 33 of the same size as the filling opening of the mold II to which itis directly connected. The rectangular groove 33 in the cover plug 43 may increase in depth and width toward the bottom of the plug 43 (Figure 3) so as to provide a tapered conduit 53 in this side of the ladle leading from the chamber 43 to a discharge aperture 55 which is coincident with the filling aperture of the mold.

The shell as of the ladle I3 is preferably supported in a basket-like metal frame which may consist of a metal hoop 51, and a plurality of longitudinally extending metal straps 33-3! which have inwardly turned ends 32 at their lower end for attachment to the bottom of theshell 33. A transversely extending bar 33 is carried by the bottom of the shell 33' and is adapted to be engaged by a latching lever 34 which is pivotally mounted by means of a bolt 35 on one of the legs i1 of the frame member 13.

The latching bar 34 has a slot 33 which engages the bar 33 when the ladle is in vertical position I as shown 'in Figure 2, to retain it in this position against any possibility of moving or tipping. A tenson coil spring 31 has one end secured to the frame member 13 at the bolt 33 and the other end pivotally secured to the latching lever 34 by means of a block .33 secured to the end of the spring and pivotallymounted by means of the pivot pin 33. The latching lever is thus urged into latching position shown in full lines in Figure 2 but may be moved out'of engagement with its keeper "by pressing downward on the latching lever 34 with thefoot.

The hoop 31 is. secured to the vertical frame members 53-31 at their intersection by suitable bolts or by welding, and the vertical frame members 53-3I may b turned outwardly at their upper ends and secured by means of bolts to a cover plate 13 which may project beyond the outer wall of the shell 33 suificiently to engage the laterally turned ends 1| of the frame members 53-3l.

The cover plate 13 is provided with a rectangular aperture 12 located to register with the discharge apertur 55 in the ladle I3 and plug 43 and the conduit extending through the cover plate 13 is made continuous and smooth from the conduit 53 into the filling opening of the mold ,l i, the aperture 12 being of the same size as the filling opening of the mold H.

The cover plate 13 holds the plug 43 firmly in place and it is also provided with an aperture 13 (Figure 5) for passing the gas burner nozzle 34. The bolts 14 which secure the frame members 53-3l to the cover plate 13 may also be used to secure to the top of the cover plate a plurality of metal bars 15-13. These-metal bars may be of rectangular section and they are a part of the structure utilized with other bars for securing the mold directly to the top of the ladle.

For example, the metal bar 15 may be secured to the cover plate 13 by a plurality of bolts passing through the bar and threaded into the cover plate and the bar 15 is preferably located with the edges of the discharge aperture 12 as it is intended to hold one-half of the mold II in proper position in registry with the aperture 12 at its lower end.

The mold I I comprises a pair of parts 8 I, 82 and I the lower and left corner 88 of the mold half 8| half mold member 8| when it is in the position of Figure 2. For this purpose, the bar members 18 and 11 may be braced by having anupwardly extending frame member 84 at the end of each bar member 18, 11, the upper end of which is secured to another horizontally extending bar 85 by means of screw bolts 88. The bar members 18, 11 may be secured together at regularly spaced points by transversely extending bars 81, 88, 88, and the inner ends of the bars 85 may be secured to the fixed mold member 82 by a rivet or bolt 83.

The bars 18, 11 and the bars 85 are spaced from each other laterally sufiiciently so that the mold member 8| may lie between them and the vertical frame members 84 project above the bars 85 to provide a stop surface 88 for engagement with the laterally projecting pipe 8| carried by mold member 8|. Thus, the mold member 8| is prevented from sliding endwise toward the left off the supporting framewhich' com-- prises the bars 18, 11, 85, 84 and others.

The horizontal supporting frame for'the mold member 8| may be indicated in its entirety by the numeral 82. The mold member 82 is preferably fixedly supported on the ladle 18 by means of a vertically extending frame on each side. This frame may consist of the vertically extending frame members 8386 (Figure 6) which are secured to th horizontally extending bars 81, 88 on the cover plate 18. I

The bars 83, 84 are secured together at regularly spaced points and the bars 85, 86 are secured together at regularly spaced points by means of screw bolts and horizontal frame members 88-|8I. The frames at each side are secured together by the transversely extending frame member I82.

The uppermost transverse frame members 88 (Fig. 3) are joined by a frame member I83 which may have a beveled surface I84 on the side which engages the fixed mold member 82. The fixed mold member is preferably substantially rectangular in elevation and comprises a metal member provided with a plane, smooth and polished surface I 85 forming on of the sides of the mold cavity I86.

The two mold members 8| and 82 are made of metal having a higher melting point than the metal which is to be .cast into plates. For example, when casting aluminum and certain other alloys," cast steel molds may be used. The mold member 82 is preferably provided with a rearwardly extending reenforcing border flang I81 extending on all the four edges of the body plate I88 and it is also preferably provided with a plurality of transversely extending reenforcing ribs I88. Vertically extending reenforcing ribs may also be employed for the purpose of preventing the warping of the mold, and the lower edge of the fixed mold 82 is preferably beveled as at II8 so that it will fit against the cover plate 18 when the mold is disposed at an angle as shown.

The face I85 of this mold 82 registers with the opening 12 in the cover plate 18 which in turn registers with the discharge opening 55 from the chamber 43 of the ladle. The width of the mold members 8 I, 82 is such that the mold cavity I88 is as wide as the discharge openings '12 and 55 are long. The thickness of the mold cavity I 86 isthe same from top to bottom and is of such thickness that the lower open end of the mold has the walls of its cavity in registry with the edges of the opening 12 in th cover plate 18.

The fixed mold 82 rests against the frame member I83 at the top and against the cover 'border flange III on all sides, and reenforcing member 8| of screw bolt- I23.

flanges II5. This movable mold member, however, is preferably provided with a mold wall ||6 which extends across the top of the mold and down both sides of the mold member 8|, but is open at the bottom, thereby defining a mold filling opening II1. This mold member has its lower border flange II4 provided with arr-oppositely beveled surface II8 so that it may fit against the cover plate 18. The width of this surface H8 is such that when the toe 83 of the mold 8| engages the bar 15, the filling opening 1 is in registry with the opening 12 in the cover plate 18. Thus, the mold II is adapted to have a filling opening which is of substantially the same size as the discharge opening in the ladle, the reaons for which will be described hereinafter.

The movable m'old 8| maybe provided with a handle 8| which is of sufficient length to project laterally from both sides of the mold II. It may comprise a metal pipe which is secured to the vertically extending reenforcing flanges ||4 (Fig. 1) by a plurality of screw bolts I28 which pass through apertures of the pipe and are threaded into the flanges Ill. The handle 8| also serves the purpose of providing a support for the mold 8| when it is moved into the dotted line position of Fig. 2, resting on the frame members 85 by means of handle 8|.

The fixed mold 82 is preferably provided with means for holding the movable mold 8| in tight engagement ,with it as' follows: At theupper end of the fixed mold 82, there is secured to its rear side on each of the reenforoing ribs II4, an upwardly extending metal bar H9. Each of these bars and its assembled parts are identical so that only one need be described. Each bar H8 is secured by means of screw bolts |2I passing through the bar and threaded into the ribs II4 of mold member 82. At its upper end the bar II8 pivotally supports a lever I22 by means wedging member I24 by means of screw bolt I25. Wedging lever I24 has its lower inner end beveled at I26 and the lever I22 may have a fiber extension I21 for grasp by the hands of the Lever I22 carries a pivoted a keeper bar I38 which may b secured thereto by welding or any convenient fastening means. The operation of the securing means is as follows:

The wedging lever I24 engages the rib II4 of the expansion of the mold when the hot metal is poured into the mold.

The supporting framework for the ladle I8 also includes a pair of upwardly extending frame members I3I, I32, secured by means of screw bolts to the ladle shell 39 at the bottom and to the band 51. The frame members I3I, I32, preferably extend upward beyond the cover plate 18 where they may be bent outwardly slightly as indicated at I33, I 34, and provided with the horizontalhandle portions I35, I35.

Thus, the ladle and mold assembly has a handle I35, I36 at each end which maybe grasped by a pair of operators or either of' them intilting the ladle and mold from the position of Fig. 3 to Fig. 5.

The mold II is also preferably provided with a pair of similar wedging members, one located at each side of the mold. In this case, the fixed mold is provided with a pair of forwardly extending strap members I31, I38, joined by a transverse strap I39 to form a keeper. similar to I28, I29, I38, previously described.

A pivoted lever I48 comprising a pair of straps I4I, I42 spaced and secured to a handlebar I43 is pivotally mounted on a frame member I44 by means of a screw bolt I45. A similar wedging member I46 extends between the straps I31, I38 and inside the strap I38 to engage the mold BI and this wedging member I46 is pivotally mounted on lever I48 by screw bolt I41.

The frame member I44 may be a fixed member carried by the vertically extending bars 96. In this case the action of the wedging' members is the same as described with respect to the wedging members I24 at the top, there being suflicient space between the handlebars I33, I34 and the mold to permit the necessary pivotal movement of the levers I48.

The interior of the mold cavity I86 in the mold member 8| likewise has its surfac I48 in a substantially plane, smooth and polished condition, and the same is true of the inner surface I49 of the border flanges H at the and and both sides. Thus, the mold cavity I86 is of uniform cross-section from top to bottom and of uniform size.

The angular tilt of the mold cavity I86 with respect to the top of the ladle I8 is preferably such that when theladle and mold are tilted, the free surface I58 of the molten metal I5I is adapted to well upward into the mold as the tilting progresses. The metal does not, therefore, run down to the end I43 of the mold cavity I86, but it moves upward into the cavity in a solid stream of uniform cross-section until the cavity is entirely filled and thereafter the continued tilting of the mold to the position of Fig. 5 permits/a pressure to be placed on the metal in the mold which is determined by the head of metal above the mold cavity in the ladle in Fig. 5.

The cover plate 18 may be provided with a sliding cover I52 slidably mounted in guides I53 and provided with a slot I64 for engaging the gas burner pipe. The cover plate I52 may be provided with a handle I55 so that it may be slid to the open or theclosed position by means of the handle. Thus, the burner opening may be closed, if desired, or, ifnecessary, to prevent the spilling of the metal out of the burner opening when the mold is tilted to the position of Fig. 5.

The operation of the apparatus is as follows: The ladle I8 is preferably preheated by means of the gas burner 54, the flame 53 of which plays into the cavity 43. Metal may be melted in a separate furnace and a suitable supply of clean molten metal such as that provided by clean scrap or by ingots, may be placed in the cavity 43 after which the cover plug 48 and cover plate 18 may be secured in place. The burner 54 is then again directed into the ladle cavity 43 and the fia'me is reflected from the free surface I58 of the molten metal into the mold cavity I85.

The apparatus may be preheated by means of this flame and by casting 'a few plates to bring it to the proper temperature. Thereafter, the casting operation may be carried out as follows: The mold having been closed and secured by means of the wedges, the ladle and mold are tilted gradually from the position of Fig. 3 in a counter-clockwise direction. As the ladle is tilted, the free surface of the molten metal III is, of course, maintained in horizontal" position, and as the mold is lowered, this free surface rises in the mold cavity I86 due to the tilted position of the mold on the ladle.

The rising continues duringthe tilting operation until the mold is completely filled, without any splashing or separation of any part of the metal from the solid stream which enters the mold at the bottom and moves uniformly up through the mold until the mold is completely filled. The airor gas is expelled from the crack between the mold halves by the pressure of the molten metal which is sufflcient to expel the air or gas. i

As the tilting is continued 'downward'to the position of Fig. 5, after the mold has been filled, a predetermined pressure is placed upon the metal in the mold and while the metal in the mold cools, pressure is continued until the shrinkage is completely taken up by the head of metal under pressure applied to the mold.

The casting in the mold freezes from the flat surfaces of the mold inward toward the center, and if the mold is tilted backward quickly enough, a hollow plate may be formed or a hollow tube may be formed by the metal which has congealed adjacent the walls of the mold, the

molten metal running out of the inside to leave the casting hollow. Thus, the present invention may be used for making hollow castings or hollow tubes of any cross-section.

It should be understood that the cross-section of the mold may be circular for the making of hollow round pipes or it may be square or hexagonal or triangular or rectangular or any known or desired geometric form, the filling opening of the mold being of the same size and shape. The casting also congeals from the outer end of the mold, that is, the upper end in Fig. 3, toward the filling opening, the last to congeal being that portion adjacent the filling opening,

so that additional metal is supplied to the casting as it congeals and all shrinkage is taken up.

In order to permit sumcient time for this congealing, the tilting action of the mold is so carried out that a predetermined number of seconds or counts are employed, or the mold may be held for a short time in the position of Fig. before it is tilted back into the position of F18. 3.

As soon as the mold is tilted back to the upper most position, the wedges are released and the movable mold member 8| is moved away from the fixed mold 82 and the movable mold is laid upon the horizontal supp rts 85. The casting will then be lying against the fixed mold member 82 and a very short sprue may extend into the discharge opening 55 of the ladle, but a minimum amount of sprue is present and there is a minimum amount of metal wasted by sprue action.

The result is a cast metal plate of homogeneous uniform-grained structure without any segregations of impurities and without any pipe or cavity in the case of a solid casting. The present metal has been found to have an increased tensile strength and an increased purity over the metals cast according to the methods of the prior art, and the metals are particularly adapted to be used for drawing out metal cans or tubular containers such as the cans that are used for shields covering radio tubes of radio receivers.

The superlative product resulting from the use of this apparatus is attributed to the method of casting which may be carried out by the use of the present or other apparatus and which is summarized as follows:

The method is preferably carried out by means of a closed insulated ladle having a mold directly attached to the discharge opening of the ladle so that there is practically no sprue attached to the casting. The mold is of metal of a higher melting point than the metal to be used in casting, such as cast steel, for casting aluminum, and the interior surface of the mold is smooth and polished on all sides.

The cross-section of the mold is preferablyuniform from one end to the other for the casting of plates or other articles of uniform crosssection and the filling opening of the mold which is in registry with the discharge opening of the ladle, is'of the same size as the cross-section of the mold. The discharge opening from the ladle I is preferably streamlined from the ladle cavity by tilting the mold until the metal wells upward into the mold in a solid unbroken stream without any agitation or churning. The congelation of the metal may begin as it enters the mold but,

nevertheless, the solid plug of congealing metal is driven upward into the mold by the pressure of the metal in the ladle. The sliding engagement with the polished sides of the mold has a burnishing action on the finished casting.

The tilting is preferably carried out slowly so that the mold is filled slowly and when the mold is filled, the tilting is continued until the full pressure of the remaining metal in the ladle is placed on the metal in the mold.

The metal in the mold then congeals from the large plane fiat surfaces of the mold inward toward the center and from that end of the mold remote from the filling opening downto the filling opening. As the cooling of'the casting takes place and the congelation takes place, further metal is supplied to the casting to take up all shrinkage, also without any splashing or other disturbing action, and the ladle and mold are preferably held with the mold in downward position and full metal pressure applied for a short .time until congelation takes place.

depends upon the metals which are being cast v and upon the characteristics and thickness of The timing the mold and the temperatures employed.

When hollow castings, such as tubes or hol- I a given temperature.

in tilted relation to the ladle in such manner that when the mold is tilted, its filling opening is still the lowermost part of the mold and the free surface of the metal in the ladle may rise in the cavity of the mold uniformly until the mold is filled.

The ladle is filled to a predetermined level with making a few castings until the mold is suitably preheated.

The casting operation is then carried out with the mold in direct connection with the ladle and' There is no spurting of the metal out of a nozzle into themold,no forming of drops or separate oxidized particles, and the only part of the casting which is subjected to air is that small area at the end of the solid advancing stream of metal in the mold and that end portion becomes the end of the casting. I

The present method may be used for casting various types of metals and alloys and it is only necessary to use suitable molds of metal of a melting point higher than the metal to be used in casting.

As soon as the assembly is tilted back to the upper positiomthe wedges are released and the movable mold members withdrawn and the casting is pried loose from its position against the fixed mold member with its end sticking into the discharge opening of the ladle, It may then be laid upon a flat surface to cool gradually and to shrink without producing strains that might otherwise occur if it were left in the mold. The casting may be placed in a suitably heated furnace to cool gradually and it is preferably protected, in any event, from drafts and irregular cooling influences.

The flame and products of combustion tend to drive out the air and to maintain a constant supply of neutral atmosphere, comprising exhaust gases in the ladle above the free surface of the metal. The burner flame tends to maintain the ,pressure in the ladle slightly above atmospheric pressure so that gas flows out the crevices or hole surrounding the burner, and the air or oxygen cannot enter. I Q

When the-metal is to be used for drawing metal containers, the plates may be taken to a punching machine and metal slugs may be punched out of the casting. The metal slugs are then placed in suitable dies and the drawn cans or containers may be drawn without any preheating. The metal is easily worked and it may be drawn cold into containers or members of various diflerent sizes and shapes.

As distinguished from tubular members made out of blanks that came from commercial sheet metal, this drawing may be accomplished without any labor of the machinery on account of the fact that the metal is more easily worked. The large percentage of defective boxes or containers which resulted from the methods of the prior art is not present according to my method, as practically all of the containers are perfect. There is a large saving in the cost because clean scrap or ingot metal is much cheaper than the sheet metal of which the blanks were made according to the prior art.

It will thus be observed that I have invented an improved apparatus for making castings by means of which more perfect and more economical containers may be made, with less metal and at a lower cost. There is a minimum amount of waste by reason of the fact that there is hardly any sprue and the metal has a uniform grained homogeneous structure without any segregated rolling machinery into sheets of any desired gauge and width, but the amount of rolling that is necessary is very small because of the initial thin character of the plate castings. A large amount of rolling is eliminated and the cost of the metal sheets is greatly reduced.

With the present apparatus, no part of the melted metal is ever separated from the compact stream of melted metal'welling up into the mold.

If any part of the metal becomes separated from the stream, it would be surrounded with oxygen and become oxidized and would not fuse again in the mold to make such a homogeneous structure as I am able to secure.

While I have illustrated a preferred embodilow the free surface of the metal in the ladle when the ladle is tilted, and said ladle having a tapered insulated conduit leading to its discharge'opening and said filling opening and mold cavity extending upward from a point below the free surface of the molten metal in said ladle when the ladle and mold are tilted to casting position whereby the ladle and mold may be tilted and the mold filled and a casting formed with a minimum amount of sprue, the rest of the molten metal flowing backward into the ladle, said ladle and mold having their discharge and filling openings, respectively, of substantially the same size whereby the metal is adapted to pass into the mold in a solid stream to fill the mold without splashing and with a minimum amount of agitaion.

2. In a casting apparatus the combination of a ladle having an insulating lining surrounding a cavity for receiving a supply of molten metal, said ladle being movably mounted on a support and having an insulating closure provided with a discharge aperture adjacent the upper end of said ladle with a mold fixedly secured on said ladle and adapted to move with said ladle, said mold comprising a pair of separable parts formed with a casting cavity and having a filling opening at the end which engages the ladle, the filling opening of said mold and the.discharge opening of said ladle being in registry and being located below the free surface of the metal in the ladle when the ladle is-tilted, and said ladle having a tapered insulated conduit leading to its discharge opening and said filling opening-and mold cavity extending upward from a point below the free surface of the molten metal in said ladle when the ladle and mold are tilted to casting position whereby the ladle and mold may be tilted and the mold filled and a casting formed with a minimum amount of sprue, the rest of the molten metal flowing backward into the ladle, the said mold having its major axis extending at an oblique angle to the top of the ladle whereby the metal wells up into the mold when the ladle is tilted.

3. In a casting apparatus the combination of a ladle having an insulating lining surrounding a I prising a pair of separable parts formed with a ment of my invention, many modifications may be made without departing from the spirit of the invention, and I do not wish to be limited to the precise details of construction set forth, but desire to avail myself of all changes within the scope of the appended claims.

a casting cavity and having a filling opening at the end which engages the ladle, the filling opening of said mold and the discharge opening of said ladle being in registry and being located becasting cavity and having a filling opening at the end which engages the ladle, the filling opening of said mold and the discharge opening of said ladle being in registry and being located below the free surface of the metal in the ladle when the ladle is tilted, and said ladle having a tapered insulated conduit leading to its discharge opening and said filling opening and mold cavity extending upward from a point below the free surface of the molten metal in said ladle when the ladle and mold are tilted to casting position whereby the ladle and mold may be tilted and the mold filled and a casting formed with'a minimum amount of sprue, the rest of the molten metal flowing backward into the ladle, said discharge opening of the ladle being located at one side of said ladle adapted to be tilted downward when the ladle is moved and said mold extending away from its filling opening toward the other side of said ladle whereby the free surface of the metal in the ladle rises gradually into the mold when the ladle is tilted until the mold is filled.

4. In a-castlng apparatus the combination of a ladle having an insulating lining surrounding a cavity for receiving a supply of molten metal,

said ladle being movably mounted on a support and having an insulating closure provided with a discharge aperture adjacent the upper end of said ladle with a mold fixedly secured on said ladle and adapted to move with said ladle, said mold comprising a pair of separable parts formed with a casting cavity and having a filling opening at the end which engages the ladle, the filling opening of said mold and the discharge opening of said ladle being in registry and said ladle having a tapered insulated conduit leading to its discharge opening and said filling opening and mold cavity extending upward from a point below the free surface of the molten metal in said ladle when the ladle and mold are tilted to casting posltion whereby the ladle and mold may be tilted and a casting formed with a minimum amount of sprue, the rest of the molten metal flowing backward into the ladle, said discharge opening of the ladle being located at one side of said ladle adapted to be tilted downward when the ladle is moved and said mold extending away from its filling opening toward the other side of said ladle whereby the free surface of the metal in the ladle rises gradually into the mold when the ladle is tilted until the mold is filled, said ladle and mold being movable into a position where the mold is substantially below the supply of metal in the ladle so that an additional supply of metal may be supplied to the mold to take up shrinkage as the casting hardens in the mold.

5. In a casting apparatus the combination of a ladle having an insulating lining surrounding a cavity for receiving a supply of molten metal, said ladle being movably mounted on a support and having an insulating closure provided with a discharge aperture adjacent the upper end of said ladle with a mold fixedly secured on said ladle and adapted to move with said ladle, said mold comprising a pair of separable parts formed with a casting cavity and having a filling opening at the end which engages the ladle, the filling opening of said mold and the discharge opening of said ladle being in registry and said ladle having a tapered insulated conduit leading to its discharge opening and said filling opening and mold cavity extending upward from a point below the free surface of the molten metal in said ladle when the ladle and mold are tilted to casting position whereby the ladle and mold may be tilted and a casting formed with a minimum amount of sprue, the rest of the molten metal flowing backward into the ladle, said mold comprising a pair of metal members adapted to be preheated to a predetermined degree and to permit the formation of the casting by merely tilting the ladle and mold until the metal passes into the mold, the casting being congealed while the ladle and mold are tilted, said ladle and mold having their discharge and filling openings, respectively, of substantially the same size whereby the metal is adapted to pass into the mold in a solid stream to fill the mold without splashing and with a minimum amount of agitation.

6. In a casting apparatus the combination of a ladle having an insulating lining surrounding a cavity for receiving a supply of molten metal, said ladle being movably mounted on a support and having an insulating closure provided with a discharge aperture adjacent the upper end of said ladle with a mold fixedly secured on said ladle and adapted to move with said ladle, said mnld comprising a pair of separable parts formed with a casting cavityv and having a filling opening at the end which engages the ladle, the filling opening of said mold and the discharge opening of said ladle being in registry and said ladle having a tapered insulated conduit leading to its discharge opening and said filling opening and mold cavity extending upward from a point below the free surface of the molten metal in said ladle when the ladle and mold are tilted to casting position whereby the ladle and mold may be tilted and a casting formed with a minimum amount of sprue, the rest of the molten metal flowing backward into the ladle, said discharge opening of the ladle being located at one side of said ladladapted to be tilted downward when the ladle is moved and said mold extending away from its filling opening toward the other side of said ladle whereby the free surface of the metal in the ladle rises gradually into the mold when the ladle is tilted until the mold is filled, said ladle and mold being movable into a position where th mold is substantially below the supply of metal in the ladle so that an additional supply of metal may be supplied to the mold to take up shrinkage as the casting hardens in the mold, said ladle and mold having their discharge and filling openings, respectively, of substantially the same size whereby the metal is adapted to pass into the mold in a solid stream to fill the mold without splashing and with a. minimum amount of agitation.

7. An apparatus for making thin metal plates comprising a closed ladle having an insulating lining surrounding a cavity adapted toreceive a supply of molten metal, said ladle having a discharge opening located at one side thereof, a mold comprising separable members formed with a cavity complementary to that of a thin metal plate, said mold cavity having a filling opening at one of its edges and said filling opening and mold cavity extending upward from a point below the free surface of the molten metal in said ladle when the ladle and mold are tilted to casting position, said filling opening being in registry with the discharge opening of said ladle and said ladle discharge opening being of substantially the same size as said filling opening.

8. An apparatus for making thin metal plates comprising a closed ladle having an insulating lining surrounding acavity adapted to receive a supply of molten metal, said ladle having a discharge opening located at one side thereof, a mold comprising separable members formed with a cavity complementary to that of a thin metal plate, said mold cavity having a filling opening at one of its edges and said filling opening and mold cavity extending upward from a point below the free surface of the molten metal in said ladle when the ladle and mold are tilted to casting position, said filling opening being inregistry with the discharge opening of said ladle and said ladle discharge opening being of substantially the same size as said filling opening, one of said mold members being fixedly secured to said ladle and the other of said mold members being removable, said removable mold member having the cavity formed therein.

9. An apparatus for making thin metal plates comprising a closed ladle having an insulating lining surrounding a cavity adapted to receive a supply of molten metal, said ladle having a discharge opening located at one side thereof, a mold comprising separable members formed with a cavity complementary to that of a thin metal plate, said mold cavity having a filling opening at istry with the discharge opening of said ladle and said ladle discharge opening being of substantially the same size as said filling opening, one of said mold members being fixedly secured to said ladle and the other of said mold members being removable, said removable mold member having the cavity formed therein, and wedging means movably secured to said fixed mold member for engaging said removable mold member and holding it in releasable engagement with the fixed mold member.

10. An apparatus for making thin metal plates comprising a closed ladle having an insulating lining surrounding a cavity adapted to receive a supply of molten metal, said ladle having a discharge opening located at one side thereof, a mold comprising separable members formed with a cavity complementary to that of a thin metal plate, said mold cavity having a filling opening at one of its edges and said filling opening and mold cavity extending upward from a point below the free surface of the molten metal in said ladle when the ladle and mold are tilted to casting position, said filling opening being in registry with the discharge opening of said ladle and said ladle discharge opening being of substantially the same size as said filling opening, said mold members comprising metal members having a smooth polished cavity surface whereby the surface of the casting is burnished as the metal moves into the cavity.

11. An apparatus for making thin metalplates comprising a closed ladle having an insulating lining surrounding a'cavity adapted to receive a supply of molten metal, said ladle having adischarge opening located at one side thereof, a

, mold comprising separable members formed with a cavity complementary to that of a thin metal plate, said mold cavity having a filling opening at one of its edges, said filling opening being in registry with the discharge opening of said ladle and said ladle discharge opening being of substantially the same size as said filling opening, said mold filling openingpxtending over the full thickness of the metal plate and the full width of the metal plate whereby the cross-section of the stream of metal is not altered as it passes into the mold.

12. An apparatus for making thin metal plates comprising a closed ladle having an insulating lining surrounding a cavity adapted to receive a supply of molten metal, said ladle having a diswith the discharge opening of said ladle and said ladle discharge opening being of substantially the same size as said filling opening, said ladle also having a heater opening located oppositely to said discharge opening whereby a heating means may be applied to the ladle and the heated gases from the heater may be deflected from the free surface of the metal in the ladle up into the discharge opening and mold.

14. In a casting apparatus, the combination of a support with a heat insulated container movably mounted on said support for tilting movement, with a mold fixedly secured to said container to be tilted with the container, said mold communicating directly with the interior of said insulated container, and said mold extending upwardly from its filling opening communicating with said container, the mold having a cavity of substantially uniform cross section, and the filling opening being of substantially the same size and shape as the cross sectional size and shape of said cavity. said container being arranged and constructed to receive a supply of the molten metal, the molten metal welling up into the mold from a point below the free surface of the molten metal in the container when the container and mold are tilted in a predetermined direction, and the container being maintained in elevated position above aid mold to place a predetermined head of molten metal on the molten metal in the mold, while the metal is congealing in the mold, to take up the shrinkage, the casting in the mold congealing from the sides of the casting inward toward the center and from a point most remote with respect to the filling opening inwardly toward the filling opening, th container and mold being tilted back with the'mold above the free surface of the metal, when the casting has congealed to permit the molten metal of the sprue to flow back into the container.

15. In a casting apparatus, the combination of a support with a heat insulated container movably mounted on said support for tilting movement, with a mold fixedly secured to said container to be tilted with the container, said mold communicating directly with the interior of said insulated container, and said mold extending upwardly from its filling opening communicating with said container, the mold having a cavity of substantially uniform cross ection, and the filling opening being of substantially the same size and shape as the cross sectional size and shape of said cavity, said container being arranged and constructed to receive a supply of the molten metal, the molten metal welling up into the mold from a point below the free surface of the molten metal in the container when the container and mold are the free surface of the molten metal in said ladle y comprising a closed ladle having an insulating lining surrounding a cavity adapted to receive a supply of molten metal, said ladle having a discharge opening located at one side thereofva mold comprising separable members formed with a cavity complementary to that of a thin metal plate, said mold cavity having a filling opening at one of its edges, said filling opening being in registry tilted in a predetermined direction, and the container being maintained in elevated position above said mold to plac a predetermined head of molten metal on the molten metal in the mold, while the metal is congealing in the mold, to tak up the shrinkage, the casting in the mold congealing from the sides of the casting inward toward the center and from a point most remote with respect to the filling opening inwardly toward the filling opening, the 'container and mold being tilted back with the mold above th free surface of the metal, when the casting ha congealed to permit the molten metal of the sprue to flow back into the container, the said container having its chamber provided with a heat insulated cover for excluding the atmosphere, said cover being removable to effect a kimming of the molten metal.

16. In a casting apparatus, the combination ofa support with a heat insulated container movably mounted on said support for tilting movement, with a mold fixedly secured to said container to be tilted with the container, said mold communicating directly with the interior of said insulated container, and said mold extending upwardly from its filling opening communicating with said container, the mold having a cavity of substantially uniform cross section, and the filling opening being of substantially the same size and shape as the cross sectional size and shape of said cavity, said container being arranged and constructed to receive a supply of the molten metal, the molten metal welling up into the mold from a point below the free surface of the molten metal in the container when the container and mold are tilted in a predetermined direction, and the container being maintained in elevated position above said mold to place a predetermined head of molten metal on the molten metal in the mold, while the metal is conaealing in the mold, to take up the shrinkage, the casting in the mold congealing from the sides of the casting inward toward the center and from a point most remote with respect to the filling opening inwardly toward the filling opening, the container and mold being tilted back with the mold above the free surface of the metal, when the casting has congealed to permit the molten metal of the sprue to flow back into the container, the major axis of the mold also extending diagonally with respect to the major axis of the container, and the filling opening of the mold being located on the side of the container toward which the top of the container is to be tilted.

CARL WES SEL. 

